INDUSTRIAL
DT Series Technical Manual
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DT Series Technical Manual
Introduction
Features & Benefits
Product Line Overview
Material Specifications
General Specifications
Ordering Information
Insert Arrangements
Contacts & Application Data
5
6
7, 8
9
4
5
2, 3
3
Contact Retention System
Assembly Contact Insertion / Removal
Accessories
Shrink Boot Adaptor
Removal Tools / Sealing Plugs
DT Mounting Clips
Back Shells
10
11
12
12
12
13
14, 15
Deutsch DTM Series of transportation connectors feature a miniature contact with an enhanced design based on the world class, field-proven Deutsch DT Series.
The DTM is the connector to be used in harsh environmental application where reliable signal circuits are critical to operating performance. Typical applications include on or around the engine, the transmission and under the hood.
An environmentally-sealed connector designed specifically for cable to cable applications on the engine or transmission, under the hood, on the chassis or in the cab. On signal level circuits in harsh environmental conditions, where even a small degradation in connection may be critical, the Deutsch DT Series general purpose connectors will provide the reliability and performance at the lowest cost.
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DT Series Technical Manual
Deutsch’s DTP Series connectors are the answer to all of your most demanding power application requirements.
DTP Series connectors offer the proven reliability and quality of Deutsch’s DT Series, combined with the added flexibilty of using power contacts.
Utilizing the Deutsch DT receptacle shell, Deutsch has combined the rugged characteristics of the DT product line with a bussing device allowing the elimination of various harness splices. By using internal stamped bussed contacts this product can be configured in whatever arrangement meets your individual needs in the DT shell size that matches your requirements. Complete bussing flexibility in a compact, economical package.
Deutsch developed the DTHD Series for those applications requiring a complete, environmentally sealed, single power circuit termination. The plug features an integral coupling latch that provides tactile and audible feedback during coupling. The rugged thermoplastic receptacle is designed as an inline for cable to cable applications and is supplied with an integral Vee-Groove to accept mounting, clips, brackets and flanges.
Features
Integral Connector Latch
Rugged Thermoplastic Housing
-55 o C to +125 o
C Operating Temperature
Available Configurations:
DTM/DT 2, 3, 4, 6, 8 & 12 - Size 20/16
DTP 2 & 4 - Size 12
DTHD 1 - Size 4, 8 & 12
Silicone Seals:
DTM: Accepts AWG 22 - 16 wire
DT: Accepts AWG 20 - 14 wire
DTP: Accepts AWG 14 - 10 wire
DTHD: Accepts AWG 14 - 6 wire
Crimp Contacts with Option of Gold or Nickel
Finish, Solid or Stamped Construction
Current rating all contacts @ 125 0 C no derating
DTM - 7.5 Amps
DT - 13 Amps
DTP - 25 Amps
DTHD - 25 to 100 Amps
Fail-Safe Secondary Locks All (Except DTHD)
Hand Insertable/Removable Contacts
Budget Minded
Benefits
Tactile and Audible Assembly Feedback
Field Proven Long Service Life
Engine Compartment Rated
Meets Most Harness Design Requirements
Superior Environmental Seal
Seals on .053” to .120 dia.(1.35mm to 3.05mm)
Seals on .053” to .145 dia.(1.35mm to 3.68 mm)
Seals on .097” to .170 dia.(2.46mm to 4.32mm)
Seals on .134 to .292 dia. (3.40mm to 7.42mm)
Low Costs, High Reliability Terminals for Data &
Signal Transmission
Meets Most Signal Requirements
Positive Contact Retention
No Special Tools Required (Except DTHD)
Low Installation Costs
A STEP AHEAD

DT Series Technical Manual
Deutsch DTM Series of transportation connectors feature a miniature contact with an enhanced design based on the world class, field-proven Deutsch “DT Series”.
The DTM is the connector to be used in harsh environmental applications where reliable signal circuits are critical to operating performance. Typical applications include on or around the engine, the transmission and under the hood. In fact, everywhere data signals or critical electronic circuits go, the field proven
Deutsch design of the DTM will provide reliable peak connector performance.
The low cost, size 20 contacts terminate AWG 16 to 22 gauge wire (0.5mm
2 to 1.5mm
2 ). Closed entry socket (female) contacts featuring spring action fingers are protected by a stainless steel hood. This allows for positive axial alignment while mating and prevents probe damage during testing.
Thermoplastic housings offer a wide operating temperature range (-55 0 C to +125 0 C). Silicone rear wire and internal peripheral interface seals allow the DTM to withstand moisture and fluids.
Building on both the DT and DTM design strengths, the DTP connector line was developed to fill the need for higher amperage, multi-pin, inexpensive connectors. The series meets the same specifications as the DTM and DT but offers the designer the ability to use multiple 12 gauge contacts, each with a 25 amp continuous capacity, within a single shell.
Based on the DTM overall design, it offers the protected interfacial seal located within the receptacle shell. Standard multi-seal grommet is used in both the plug and receptacle. Currently available in two and four pin configurations.
These standard “DT” receptacle shells feature internal pin type contact buss bar arrangements that allow common connections from 3 to 12 size 16 contacts. Buss bars are available in standard nickel or gold to match common Deutsch Industrial contacts.
Other features include the use of standard “DT” plugs to mate with these environmental receptacles. Plugs with any Deutsch modification are intermatable.
Deutsch DT Series of environmentally-sealed, connectors are designed specifically for cable to cable applications on the engine or transmission, under the hood, on the chassis or in the cab.
Where signal level circuits in harsh environmental conditions, where even a small degradation in connection may be critical, the Deutsch DT Series general purpose connectors will provide the reliability and performance at the lowest cost.
Thermoplastic (-55 0 C to + 125 0 C rated) housings and silicone seals are used to allow the connector to withstand conditions of extreme temperature and moisture. The connector may be employed with either solid-copper crimp type contacts for critical circuits or budget-minded stamped and formed contacts. In either selection, the spring action is designed in the socket and shrouded by a stainless steel hood that provides closed entry for positive axial alignment during mating, and eliminates probe damage from occurring. Contact insertion and withdrawal require no special tools and are retained in locked position by dielectic fingers, molded as an integral part of the housing. Secondary locks are assembled at the mating interfaces. If by chance the secondary locks are not properly seated during assembly, they will be pressed into locked position during the mating of the connector.
Deutsch developed the DTHD Series for those applications requiring a complete, environmentally sealed, single power circuit termination.
DTHD plugs and receptacles can be permanently assembled with thermoplastic end caps that prevent removal of the silicone wire seal grommets. Designed for diesel engine, electronic fuel injectors, automatic transmissions, ABS brakes and other applications that involve fuel and oil exposure. These end caps provide the additional reliability required for critical wiring circuits.
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DT Series Technical Manual
Plug/Receptacle
Shell:
Wedge:
Thermoplastic
Thermoplastic
Grommet: Silicone Rubber
Contacts
Pin:
Socket:
Finish:
Copper Alloy
Copper Alloy
Nickel (optional - gold) Plated
Sealing Plugs
Thermoplastic: (All sizes)
Dielectric Withstanding Voltage
Current leakage less than 2 milliamps at 1500 VAC
Insulation Resistance:
1000 megohms minimum at 25 0 C.
Current Rating (Contact current rating @ 125 0 C (continuous)
Size 20: 7.5 amps
Size 16: 13 amps
Size 12: 25 amps
Size 8: 60 amps
Size 4: 100 amps
Submersion:
Properly wired and mated connection will withstand immersion under three feet of water without loss of electronic qualities or leakage.
Fluid Resistance:
Connectors show no damage when exposed to most fluids used in industrial applications.
Vibration:
No unlocking or unmating and exhibits no mechanical or physical damage after sinusoidal vibration levels of 20 G’s at 10 to 2000
Hz in each of the three mutually perpendicular planes. No electrical discontinuities longer than 1 microsecond.
Temperature:
Operative at temperatures from -55 0 C to +125 0 C. Continuous at rated current.
Contact Retention:
Contacts withstand a minimum load of:
20 lbs (89N) for size 20
25 lbs (111N) for size 16
30 lbs (133N) for size 12
35 lbs (156N) for size 8
35 lbs (156N) for size 4
Thermal Cycle:
No cracking, chipping or leaking after 20 test cycles from
-55 0 C to +125 0 C.
Durability:
No electrical or mechanical defects after 100 cycles of engagement and disengagement.
CONTACT
SIZE
WIRE GAUGE
AWG(mm 2 )
Test Current
(Amps)
Resistance (mV)
Solids
20
20
16
12
8
4
22 (.35)
20 (.50)
18 (.80)
16 (1.0)
20 (.50)
18 (.80)
16 (1.0)
14 (2.0)
14 (2.0)
12 (3.0)
8 (8.60)
10 (5.60)
6 (13.0)
5.0
7.5
7.5
7.5
7.5
10
13
13
18
25
60
60
100
N/A
60
60
60
60
60
60
60
60
60
60
60
60
Resistance (mV)
Stamped & Formed
100
100
100
100
100
N/A
N/A
N/A
100
100
100
100
100
#20
#16
CONTACT SIZE
RECOMMENDED WIRE INSULATION O.D.
N-SEAL E-SEAL
.053-.120
(1.35-3.05)
.088-.145
(2.24-3.68)
N/A
.053-.120
(1.35-3.05)
#12
.134-.170
(3.40-4.32)
.097-.158
(2.46-4.01
)
#8
#4
.190-.240
(4.83-6.10)
.280-.292
(7.11-7.42)
N/A
N/A
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DT Series Technical Manual
DTM 06 - 2 S * - ****
Series Prefix
04 = Receptacle
06 = Plug
Number of Contacts
Special Modifications
Polarizing Position (If Applicable)
08 + 12 Only
Contact Type
P = Pin Receptacle Only
S = Socket Plug Only
DT 06 - 2 S * - ****
Series Prefix
04 = Receptacle
06 = Plug
Number of Contacts
Special Modifications
Polarizing Position
(If Applicable)
Contact Type
P = Pin Receptacle Only
S = Socket Plug Only
DTP 06 - 2 S * - ****
Series Prefix
04 = Receptacle
06 = Plug
Number of Contacts
Special Modifications
Polarizing Position
(If Applicable)
Contact Type
P = Pin Receptacle Only
S = Socket Plug Only
DTHD 06 - 1 - 4 S - ****
Series Prefix
Special Modifications
04 = Receptacle
06 = Plug
Single Terminal
Contact Size
4 = Size 4
8 = Size 8
12 = Size 12
Contact Style
P = Pin Receptacle Only
S = Socket Plug Only
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DT Series Technical Manual
2
2 size 20
3
3 size 20
4
4 size 20
6
6 size 20
8
8 size 20
12
12 size 20
2
2 size 16
3
3 size 16
4
4 size 16
6
6 size 16
8
8 size 16
12
12 size 16
2
2 size 12
4
4 size 12
1
1 size 4
1
1 size 8
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1
1 size12

DT Series Technical Manual
Standard DT Receptacles Bussed to Customer Specifications
DEUTSCH
4 PIN
DEUTSCH
6 PIN
DEUTSCH
6 PIN
8 7 6 5
1 2
DEUTSCH
3
8 PIN
4
8 7 6 5
1 2
DEUTSCH
3
8 PIN
4
8 7 6 5
1 2
DEUTSCH
3
8 PIN
4
12 11 10 9 8 7 12 11 10 9 8 7
1 2 3
DEUTSCH
4
12 PIN
5 6 1 2 3 4
DEUTSCH
12 PIN
5 6
12 11 10 9 8 7
1 2 3
DEUTSCH
4 5 6
12 PIN
Arrangements shown are currently available. For additional arrangements contact factory.
ALL PART NUMBERS ARE
FOR “BLACK”
MAX CURRENT RATINGS
4 PIN = 26 AMPS
6 PIN = 39 AMPS
3 PIN = 13 AMPS
8 PIN = 52 AMPS
5 PIN = 26 AMPS
4 PIN = 26 AMPS
3 PIN = 13 AMPS
12 PIN = 76 AMPS
6 PIN = 39 AMPS
3 PIN = 13 AMPS
NICKEL BUSS P/N
DT04-4P-EP13
DT04-6P-EP13
DT04-6P-EP14
DT-8PB-P021
DT04-8PB-PO28
DT04-8PB-P026
DT04-3P-***
DT04-12PB-P021
DT04-12PB-P026
DT04-12PB-P030
GOLD BUSS P/N
DT04-4P-EP12
DT04-6P-EP12
DT04-6P-EP15
DT04-8PB-P016
DT04-8PB-PO29
DT04-8PB-P027
DT04-3P-***
DT04-12PB-P016
DT04-12PB-P027
DT04-12PB-P031
PLEASE CONSULT FACTORY FOR AVAILABILITY AND ALTERNATE KEYING
MATING PLUG P/N
DT06-4S-****
DT06-6S-****
DT06-6S-****
DT06-08SB-****
DT06-08SB-****
DT06-08SB-****
DT06-3S-****
DT06-12SB-****
DT06-12SB-****
DT06-12SB-****
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DT Series Technical Manual
SIZE PIN
SOLID CONTACT
PART NUMBERS
SOCKET
WIRE SIZE
AWG (mm 2 )
RECOMMENDED
STRIP LENGTH
INCHES (mm)
MIN CONTACT
RETENTION
LBS (N)
REF CRIMP
TENSILE
LBS (N)
MAX RATED
AMPS AT 125 0 C
CONTINUOUS
20
20
16
16
12
8
4
0460-010-20** 0462-005-20**
0460-202-20** 0462-201-20**
0460-202-16** 0462-201-16**
0460-215-16** 0462-209-16**
0460-204-12** 0462-203-12**
0460-204-08** 0462-203-08**
0460-204-04** 0462-203-04**
16-18
(1.0-0.75)
20
(0.50)
16-20
(1.0 - 0.50)
14
(2.0)
12-14
(3.0 - 2.0)
8-10
(8.0 - 5.0)
6
(13.0)
.156-.218
(3.96-5.54)
.156-.218
(3.96 - 5.54)
.250 - .312
(6.35 - 7.92)
.250 - .312
(6.35 - 7.92)
.222 - .284
(5.64 - 7.21)
.430 - .492
(10.92 - 12.50)
.430-.492
(10.92-12.50)
* See Envelope Print 0425-205-0000. Consult factory for alternate finishes.
20
(89)
20
(89)
25
(111)
25
(111)
30
(134)
35
(156)
35
(156)
20
(89)
20
(89)
35-20
(156-89)
70
(311)
75-70
(334 - 311)
125-90
(556-400)
300
(1334)
5.0
7.5
13
13
25
60
100
Socket Pin Socket
INSPECTION HOLE
INSPECTION HOLE
Pin
SIZE
STAMPED & FORMED CONTACT
PART NUMBERS
CARRIER
STRIP
IDENTIFICATION
PIN SOCKET
WIRE SIZE
AWG (mm2)
20
20
20
20
16
16
16
16
16
16
16
16
12
12
1060-20-01** 1062-20-01**
1060-20-02** 1062-20-02**
N/A 1062-20-03**
1060-20-06** 1062-20-06**
1060-14-01** 1062-14-01**
1060-14-10** 1062-14-10**
1060-16-01** 1062-16-01**
1060-16-06** 1062-16-06**
1060-16-07** 1062-16-07**
1060-16-09** 1062-16-09**
1060-16-12** 1062-16-12**
N/A 1062-16-14**
1060-12-01** 1062-12-01**
1060-12-02** 1062-12-02**
20 - 01
20 - 02
20 - 03
20 - 06
14-16
14 -16
16 - 18
0.5 - 1.0
0.75 - 2.0
16 - 18
1.0 - 2.5
14 - 16
12 - 14
10 - 12
16 - 22
(1.5 - 0.35)
16 - 22
(1.5 - 0.35)
16 - 22
(1.5 - 0.35)
14 - 16
(2.5 - 1.0)
14 - 18
(2.0 - .75)
14 - 18
(2.0 - .75)
14 - 18
(2.0 - .75)
16 - 20
(1.0 - 0.50)
14 - 18
(2.0 - .75)
14 - 18
(2.0 - .75)
12 - 16
(2.5 - 1.0)
12 - 16
(2.5 - 1.0)
12 - 14
(4.0 - 2.0)
10 - 12
(6.0 - 4.0)
WIRE
INSULATION
O.D. RANGE
RECOMMENDED
STRIP LENGTH
INCHES (mm)
MIN CONT.
RETENTION
LBS (N)
.075 - .125
(1.91 - 3.15)
.051 - .085
(1.30 - 2.16)
.075 - .125
(1.91 - 3.15)
.075 - .125
(1.91 - 3.15)
.095 - .150
(2.41 - 3.81)
.095 - .150
(2.41 - 3.81)
.075 - .140
(1.91 - 3.55)
055 - .100
(1.40 - 2.54)
.075 - .140
(1.91 - 3.55)
.075 - .140
(1.91 - 3.55)
.075 - .140
(1.91 - 3.55)
.075 - .140
(1.91 - 3.55)
.113 - .176
(2.87 - 4.47)
.140 - .204
(3.56 - 5.18)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.175 - .225
(4.45 - 5.72)
.175 - .225
(4.45 - 5.72)
.225 - .275
(5.72 - 6.991)
.225 - .275
(5.72 - 6.99)
25
(111)
25
(111)
25
(111)
25
(111)
25
(111)
25
(111)
25
(111)
25
(111)
30
(134)
30
(134)
20
(89)
20
(89)
20
(89)
20
(89)
** = Plating Codes Consult factory for custom finish needs. Consult factory for alternate finishes
For 12 Size, see 0425-041-0000 and 0425-208-0000
For 16 Size, see 0425-039-0000, 0425-059-0000, and 0425-203-0000
For 20 Size, see 0425-059-0000 and 0425-207-0000
REF CRIMP
TENSILE
LBS (N)
MAX RATED
AMPS AT 125 0 C
CONTINUOUS
20 - 10
(89 - 45)
20 - 10
(89 - 45)
20 - 10
(89 - 45)
20 - 10
(89 - 45)
25
(111)
25
(111)
25
(111)
25 - 15
(111 - 67)
25
(111)
25
(111)
25
(111)
25
(111)
70
(311)
70
(311)
7.5
7.5
13
13
13
13
13
13
13
25
25
7.5
7.5
13
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DT Series Technical Manual
Rquired Removal Tool (See page 12)
LOCKING FINGERS
CONTACT
UNLOCKED POSITION CONTACT INSERTION
CONTACT LOCKED POSITION
TOOL INSERTED TO UNLOCK CONTACT TOOL AND CONTACT REMOVED
CONTACT
UNLOCKED POSITION
LOCKING FINGER
CONTACT INSERTION CONTACT LOCKED IN POSITION
SCREW DRIVER INSERTED TO UNLOCK CONTACT CONTACT REMOVED
A STEP AHEAD

DT Series Technical Manual
1. Grasp crimped contact approximately 1.0” (25.4mm) behind the contact barrel.
2. Hold connector with rear grommet facing you.
4. Once all contacts are in place, insert orange wedge: receptacles
- with half holes aligning with contacts. Plugs - with contacts aligning behind full holes. The orange wedge will snap into place.
NOTE: The receptacle is shown
- use the same procedure for plug.
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.
1. Remove orange wedge using needlenose pliers to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver.
A STEP AHEAD
3. Hold the rear seal in place, as removing the contact will displace the seal.

DT Series Technical Manual Accesso-
To meet the application requirements where wires are to be protected, the DT Series may be supplied with boot adaptors. These will accept shaped boots / sleeves or shrink tubing. Parts for standard or thin wall wire are available.
Part Number - Plugs Part Number - Receptacles
Number of
Ways
Basic
Part Number
4
6
2
3
8
12
DT06-2S
DT06-3S
DT06-4S
DT06-6S
DT06-8SA
DT06-12SA
Grey
Std.
Thin
Wall
-E008
-E008
-E008
-E008
-E008
-E008
-CE04
-CE04
-CE04
-CE04
-CE04
-CE04
Std.
Black
Thin
Wall
-EP11
-EP11
-EP11
-EP11
-EP11
-EP11
-CE13
-CE13
-CE13
-CE13
-CE13
-CE13
Number of
Ways
Basic
Part Number Std.
Grey
Thin
Wall
4
6
2
3
8
12
DT04-2P
DT04-3P
DT04-4P
DT04-6P
DT04-8PA
DT04-12PA
-E008
-E008
-E008
-E008
-E008
-E008
-CE04
-CE04
-CE04
-CE04
-CE04
-CE04
Std.
-EE01
-EE01
-EE01
-EE01
-EE01
-EE01
Black
Thin
Wall
-CE09
-CE09
-CE09
-CE09
-CE09
-CE09
NORMAL WIRE SEALS (N) EXTRA THIN WALL WIRE SEALS (E) SEALING PLUG
PART NO.
114010
114008
114009
SIZE
12
8
4
WIRE RANGE AWG
12-14
8-10
6
PART NO.
0411-337-1205
0411-353-0805
114009
SIZE
12
8
4
WIRE RANGE AWG
12-14
8-10
6
CONTACT SIZE
20
16 -12
8
4
Wire Sealing Range: Standard - 2.24mm - 3.68mm (0.088188” - 0.144881) wire insulation diameter
Thin wall - 1.35mm - 3.05mm (0.053149 - 0.120098”) wire insulation diameter
PART NO.
0413-204-2005
114017
114018
114019
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DT Series Technical Manual Accessories
Metal Mounting Clips
1027-001-0800 1027-003-1200 1027-004-1200
1027-005-1200 1027-014-0800
1011-026-0205
(Thru Hole)
Part Number
1011-027-0805
(Thru Hole)
Metal Mounting Clips
Used On Material
Hole O.D.
in. (mm)
1027-003-1200
DTM (all)
DT 2, 3, 4, 6, 12
DTP (all)
DTHD (all)
1027-005-1200
DTM (all)
DT 2, 3, 4, 6, 12
DTP (all)
DTHD (all)
1027-004-1200
DTM (all)
DT 2, 3, 4, 6, 12
DTP (all)
DTHD (all)
1027-001-0800 DT 8 cavity only
1027-014-0800
1027-002-0800
1027-006-0800
DT 8 cavity only
DT 8 cavity only
DT 8 cavity only
Stainless Steel
Stainless Steel
.433 (11.0)
.512 (13.0)
Steel w/Zinc Plating .512 (13.0)
Stainless Steel .433 (11.0)
Steel w/Zinc Plating
Steel w/Zinc
Steel w/Zinc
.323 (8.2)
.512 (13.0)
.512 (13.0)
1011-030-0205
(Snap Fit)
1011-310-0205
(W/Self Mounting Stud)
Part Number
Plastic Mounting Clips
Used On Material Color
1011-026-0205
DTM (all)
DT 2, 3, 4, 6, 12
DTP (all)
DTHD (all)
1011-027-0805 DT 8 Cavity Only
1011-030-0205
DTM (all)
DT 2, 3, 4, 6, 12
DTP (all)
DTHD (all)
1011-031-0805 DT 8 Pin
Plastic
Plastic
Plastic
Plastic
Gray
Gray
Black
Black
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DT Series Technical Manual Accessories
The Deutsch range of Back Shells is designed to snap fix onto the full range of standard DT connectors (i.e. without end cap). The innovative design allows each unit to accommodate several different sizes of slit or unslit corrugated tubes.
They are available for both plugs and receptacles and the options include straight (180 0 ) and right angled (90 additionally a version equipped with strain relief features 2, 3, 4 and 6 way for jacketed cables.
0 ) adaptors for 2, 3, 4, 6, 8 and 12 way,
Material: PA 6.6 / black
IP rating: IP40
Operating Temperatures: -40 to 125 0 C
Handling Temperature: -5 to 45 0 C
Connector
DT04-2P
DT06-2S
DT04-3P
DT06-3S
DT04-4P
DT06-4S
DT04-6P
DT06-6S
DT-04-8P
DT06-8S
DT04-12P
DT06-12S
Outlet
180
180
90
90
180
180
90
90
180
180
90
90
180
180
90
90
180
90
180
90
180
90
180
90
180
180
90
90
180
180
90
90
180
180
90
90
180
180
90
90
Strain Relief x x x x x x x x x x x x x x x x a
18,0
26,0
26,0
26,0
23,5
23,5
23,5
23,5
27,5
22,0
22,0
22,0
20,0
20,0
20,0
20,0
26,0
27,5
26,5
24,5
26,0
26,0
23,0
23,0
25,0
25,0
25,0
21,0
21,0
21,0
21,0
22,0
18,0
18,0
18,0
16,0
16,0
16,0
16,0
25,0
Envelope Dimensions (mm) b
17,0
L
54,5
21,5
21,5
21,5
20,0
20,0
21,0
21,0
28,0
22,0
22,0
22,0
22,0
22,0
22,0
22,0
21,5
28,0
28,5
28,5
35,5
36,5
36,0
36,0
23,0
23,0
23,0
23,0
23,0
23,0
23,0
22,0
17,0
17,0
17,0
17,0
17,0
17,0
17,0
23,0
64,0
43,0
43,0
55,5
55,5
38,0
38,0
62,0
59,5
43,0
43,0
53,0
53,0
35,0
35,0
64,0
47,5
57,0
39,5
63,5
53,0
58,5
43,5
64,5
44,0
44,0
56,0
56,0
36,0
36,0
59,5
54,5
40,0
40,0
45,5
45,5
31,0
31,0
64,5
H
-
-
50,0
50,0
-
-
50,0
50,0
-
-
45,0
45,0
-
-
45,0
45,0
-
50,5
-
49,0
-
50,5
-
50,5
-
48,0
48,0
-
-
48,0
48,0
-
-
37,0
37,0
-
-
37,0
37,0
-
Item No.
61048-23
61048-33
61048-24
61048-34
61048-25
61048-35
61048-26
61048-36
61057-23
61057-33
61057-24
61057-34
61057-25
61057-35
61057-26
61057-36
61031-23
61031-33
61031-24
61031-34
61031-25
61031-35
61031-26
61031-36
61051-23
61051-33
61051-24
61051-34
61051-25
61051-35
61051-26
61051-36
61049-33
61049-34
61049-35
61049-36
61052-33
61052-34
61052-35
61052-36
Part No.
1011-265-0405
1011-237-0405
1011-266-0405
1011-238-0405
1011-263-0405
1011-235-0405
1011-264-0405
1011-236-0405
1011-269-0605
1011-241-0605
1011-270-0605
1011-242-0605
1011-267-0605
1011-239-0605
1011-268-0605
1011-240-0605
1011-257-0205
1011-229-0205
1011-258-0205
1011-230-0205
1011-255-0205
1011-227-0205
1011-256-0205
1011-228-0205
1011-261-0305
1011-233-0305
1011-262-0305
1011-234-0305
1011-259-0305
1011-231-0305
1011-260-0305
1011-232-0305
1011-245-0805
1011-246-0805
1011-243-0805
1011-244-0805
1011-249-1205
1011-250-1205
1011-247-1205
1011-248-1205
Tube Size by Connector and Additional Length (mm) needed
L
L
L
L
H a H a a a b
Receptacle 180 0 b
Receptacle 90 0 b
Plug 180 0 b
Plug 90 0
A STEP AHEAD

DT Series Technical Manual Accessories
F
P
F
90 0
T
F
P
90 0
F
T
Pull Off Strength**
F
P
(N) Connector F
P
(N)
DT04-2P / DT06-2S
DT04-3P / DT06-3S
DT04-4P / DT06-4S
DT04-6P / DT06-6S
50 / 50
50 / 50
50 / 50
50 / 50
50 / 10
50 / 50
50 / 25
50 / 30
DT04-8P / DT06-8S
DT04-12P / DT06-12S
50 / 50
50 / 50
50 / 35
50 / 40
** Valid for unslit corrugated tubes. Follow also connector mounting instruction: no force must apply to wires and connector to maintain continuous tightness of the connection.
Tube size by connector and additional length (mm) needed
Connector NW6
DT04-2P / DT06-2S
DT04-3P / DT06-3S
DT04-4P / DT06-4S
DT04-6P / DT06-6S
DT04-8P / DT06-8S
DT04-12P / DT06-12S
Corrugated D
Tube Details P
X = Tube length needed for harness
X + 16,0
X + 18,0
X + 16,0
-
-
-
9,3
2,8
Ribs to be used for tube mounting*
NW7,5
X + 16,0
X + 18,0
X + 16,0
-
-
-
10,0
2,7
Connector
DT04-2P / DT06-2S
DT04-3P / DT06-3S
DT04-4P / DT06-4S
DT04-6P / DT06-6S
DT04-8P / DT06-8S
DT04-12P / DT06-12S
NW6
6
-
6
7
-
-
NW7,5
6
-
6
7
-
-
NW8,5
4
7
4
5
7
-
* The corrugated tube must be placed into the ribs as per the above table.
NW8,5
X + 10,0
X + 12,5
X + 10,0
X + 20,0
X + 20,0
-
11,7
2,4
NW10
X + 7,0
X + 7,0
X+ 13,0
X + 14,0
X + 24,5
-
13,0
2,7
NW10
3
5
3
3
5
7
NW13
-
-
-
X + 7,0
X + 8,0
X + 16,0
15,8
2,7
NW13
-
3
-
-
3
5
NW17
-
-
-
-
-
X + 10,0
21,2
3,3
NW17
-
-
-
-
-
3
D
NW
Tube details (sectional view)
Rib No.: 6 3 1
A STEP AHEAD
Strain Relief

INDUSTRIAL
3850 Industrial Avenue, Hemet, California 92545 Tel.: (951) 765-2250 - Fax: (951) 765-2255
Web: www.deutsch.net - Edition 2/2009
A STEP AHEAD

INDUSTRIAL
Common Contact System Technical Manual
A STEP AHEAD

Common Contact System Technical Manual
Introduction
Contents
Common Contacts
Crimp Information
General Specifications
Stamped & Formed Contacts
Solid Contacts
Crimping Instructions
P.C.B. Pins
Contact Glossary
1
1
1-5
3-4
5
6, 9-10
7-8
7-9
11
12-14
Deutsch manufactures two product styles of contacts, stamped and formed and solid. Within each style is a separate and distinct manufacturing process that allows the widest application with any Deutsch Industrial connector series.
Deutsch stamped and formed contacts are designed for use where wire termination costs are of primary concern without sacrificing reliability of electrical circuits. The stamped and formed contact series is made on a precision stamping machine using flat strip stock, then a durable and corrosion proof nickel plating is applied. Gold is an optional finish. All Deutsch
Industrial terminals protect the split socket tines with a closed entry stainless steel sleeve or sleeveless design. The stamped and formed contact style is sold on reels.
The Deutsch solid contact series is designed for use for larger wire size and heavy duty applications. This style of contact is manufactured using a cold heading process and solid copper alloy wire. The resulting contact is a closed entry design. The standard finish is nickel, with gold plating an option. All Deutsch
Industrial terminals protect the split socket tines with a closed entry stainless steel sleeve. The solid style of contact is sold in bulk.
Both contact styles terminate to wire using crimp type technology.
The only variations in Deutsch’s common contact systems are those dictated by wire gauge and contact style.
The word “common” describes the Deutsch contact system well. Solid and stamped contacts can be used interchangeably in any Deutsch connector.
The stamped and formed style includes 10 sizes each of pin and socket contacts that terminate 10-22AWG (5.0 - 0.35mm
2 ). The specific contact is determined by the outside diameter of wire insulation and conductor size. See the appropriate chart on page
5 of this manual for specific part numbers.
The solid style contact terminates wire from 6 AWG to 20 AWG
(13 - 0.5mm
2 ). The solid style is available in 6 sizes each of pin and socket. The applicable contact is determined by the size of the conductor only. See the appropriate chart on page 7 of this manual for specific part numbers.
The selection of Deutsch Industrial connectors insures that the contact termination system will be compatible. This reduces changes in the assembly of the wire harness. It also improves performance, reliability and maintainability. Critical functions to any electrical system. The use of a common contact system eliminates many of the failures reported in harnesses where hundreds of different terminations are used. The end result of selecting Deutsch is increased profits and long term performance.
A STEP AHEAD

Common Contact System Technical Manual
SOLID CONTACTS
Wire lead-in chamfer to aid wire insertion
Inspection hole Maximum diameter to prevent bending
Radius for added strength
Radius for smooth engagement
Smooth finish to minimize mating and prevent misalignment forces
- Closed entry to prevent probe damage and prevent misalignment
- Chamfered lead-in to prevent misalignment
Durable tines for superior electrical performance
Stainless steel sleeve for maximum socket tine protection
Inspection hole
Wire lead-in chamfer to aid wire insertion
Crimp barrel
Material:
Solid copper alloy
Termination Method:
Crimp
Manufacturing Method:
Cold-headed
Finish-Standard:
Nickel plated
Finish Options: a) Gold
Pin
• Solid shoulder for high tensile strength pin retention.
• Nickel plated as standard for corrosion resistance.
• Inspection hole for conductor strand visibility.
• Insulation cup not required due to integral wiring sealing connector grommet design.
• Solder is not used, eliminating flux corrosion and reducing assembly costs.
• Wire entry chamfer for all wire sizes.
• No retention tangs required, eliminating contact damage and the need for secondary locks.
Socket
Material:
Solid copper alloy
Termination Method:
Crimp
Manufacturing
Method:
Cold-headed
Finish-Standard:
Nickel plated
Finish Options: a) Gold
STAMPED CONTACTS
Insulation wings for additional wire support
Conductor wings for minimal contact resistance
Maximum diameter to prevent bending Chamfered for added strength
- Closed entry to prevent probe damage and prevent misalignment
- Chamfered lead-in to
Radius for smooth engagement prevent misalignment and prevent misalignment
Durable tines for superior electrical performance
Stainless steel sleeve for maximum socket tine protection
Conductor wings for minimal contact resistance
Insulation wings for additional wire support
Material:
Flat strip copper alloy
Termination Method:
Crimp
Manufacturing Method:
Stamped & Formed
Pin
Smooth finish to minimize mating forces
Finish-Standard:
Nickel plated Size 16 & 20
Tin/Nickel Size 12
Finish Options: a) Gold
Socket
Material:
Flat strip copper alloy with stainless steel sleeve
Termination Method:
Crimp
Manufacturing Method:
Stamped & Formed
Finish-Standard:
Nickel plated Size 16 & 20
Tin/Nickel Size 12
Finish Options: a) Gold

Common Contact System Technical Manual
DEFINITION
Crimping may be defined as the act of joining a conductor to a pin or socket contact using a mechanical tool to compress and displace metal. In a good crimp joint, there is a mutual flow of metal, causing a symmetrical distortion of wire strands and contact material. Such a joint is similar to a cold weld. Mechanical strength and good electrical conductivity are established.
easy and sure, both by the operator and by the inspector.
5) The crimping tool is universal, it accepts both pins and sockets of many types.
6) Plating thickness is not restricted, as in solder joints, so better corrosion resistance and contact reliability are achievable.
Because of the new environments to which electrical connectors are subjected, there has been a drastic change in thinking relative to the use of precision crimp joints in preference to solder.
CRIMPING CONFIGURATIONS
7) Crimping can be done anywhere even in the field, without special preparation. Terminations are replaced or modified in the field exactly as in the shop, using the same tools and the same techniques, and with the same ease of operation and certainty of results.
STAMPED & FORMED STYLE
8) Total installed and maintenance costs are lower since joining is quick and easy.
Stamped contacts use a folded type of crimp (Fig. 1). Solid contacts use 2, 4, or
8 indents (Fig. 2). The wire strands and the contact material are formed together in a solid mass with reduction of area of the wire strands. A minimum of voids exists.
Crimp Tensile Test
CRIMPING CHARACTERISTICS
Connectors utilizing either style of Deutsch crimped contacts permit the removal of these contacts several times. Modification, circuit changes, or replacement of contacts may be made with the same quality assurance as in production line assembly.
Crimping may be accomplished either with hand tools, power tools or automated power tools.
CROSS-SECTION ACROSS AXIS
FIGURE 1
SOLID STYLE
The following information is provided as an aid to manufacturing facilities that terminate Deutsch crimp type contacts.
The term “typical” is used to illustrate expected tensile strength results when crimp tooling is in good working order and properly calibrated. The term
“minimum” is used to illustrate a point at which tooling is suspected of having excessive wear, insufficient air pressure, bad calibration, etc. Minimum does not imply that the crimp is unacceptable, only that an adjustment should be made.
CRIMPED CONTACTS
Mechanically crimping contacts is now the dominant wire termination method, for some very good reasons:
1) Since no wet process is involved, corrosion is not a problem. No adhesives, fluxes or additives are used.
INDENTER CRIMP
CROSS SECTION ACROSS AXIS
FIGURE 2
CRIMP TENSILE STRENGTH
(STAMPED CONTACTS)
#20 SIZE 10-20 lbs.
#16 SIZE
#12 SIZE
15-25 lbs.
70 lbs.
The manner in which the tensile test is performed is important in order to attain valid test results. An axial load should be applied at a rate of 1.0 in./min starting from zero pounds until there is wire/ contact separations or wire breaking. Care should be taken to avoid clamping on the crimp barrel.
2) Strength, accuracy and over-all reliability of a crimped contact are controlled by the crimp tool, not the operator. The field tools (except #4 solid style) release the contact only after the full crimping cycle is completed. The tools are relatively inexpensive.
3) With smaller wire, the crimp is as strong as the wire itself.
(SOLID CONTACTS)
#20 SIZE 20 AWG
#16 SIZE 16 AWG
#12 SIZE 12 AWG
# 8 SIZE 8 AWG
# 4 SIZE 6 AWG
20 lbs.
20-70 lbs.
70-75 lbs.
90-125lbs.
300 lbs .
4) The joint can be inspected visually.
Viewing the wire through an inspection hole in the contact makes inspection quick,
A STEP AHEAD

Common Contact System Technical Manual
ACCEPTABLE CRIMP UNACCEPTABLE CRIMP
SOLID STYLE
CONDUCTOR
STRANDS VISIBLE
INDENTER CRIMP
CROSS SECTION ACROSS AXIS
CORRECT
INSULATION
GAP
(IF REQUIRED)
PROPER
INDENTS
CRIMP INSPECTION
Crimping tools are, in some case, more expensive than soldering tools, but this is more than off-set by the lower total installation and maintenance costs resulting from the crimping operation.
However, controls are required to make sure first, that the operator uses the proper crimping tools designed for the type and size contact being crimped, and then, that the pin or socket is properly inserted into the tool. The wire must be stripped of insulation and fully inserted into the contact. The usual procedure is to insert the wire into the open end of the contact, then close the crimping tool, thus crimping the wall of the contact into the wire at several points around the circumference.
When completed, correct assembly can be checked visually. The removed insulation should expose a conductor length that will pass beyond the inspection hole in the contact and still reveal
.025 - .100 (.063 - 2.54) of conductor between the contact and the insulation on the wire. The operator and inspector can thus check for:
1) Damaged wire strands.
2) Missing wire strands.
3) Wire strands not entering the contact barrel.
4) Wire not inserted to the proper depth in the contact.
When the correct tool is used for crimping, a good termination is assured.
For more detailed crimp dimensions please request a factory drawing. For Stamped and Formed Style see 0425 -*** - 0000.
For Solid Style see 0425-205-0000.
COMMON TOOLING
By selecting the Deutsch common contact system, only one style of tool is needed to remove wires. In designs like the DT and DTM
Series connectors, even this tool is eliminated. Hand crimp tools are used to crimp different types of contacts to the wire end.
For automation, semi and full automatic crimping equipment is available that will process thousands of wire terminations per hour.
COMMON PROCESSING
Using the Deutsch contact means that the way an O.E.M. supplier attaches a wire to this terminus never varies. This procedural standard allows harness assemblers to become highly proficient in terminating Deutsch connectors.
STAMPED AND FORMED TYPE
B
B
CRIMP HEIGHT
MICROMETER
BLADE DIMENSIONS
CONDUCTOR
STRANDS
NOT VISIBLE
FLAYED
WIRE
SOLID TYPE
A
A
PIN / SOCKET
SIDE VIEW
A
A
.025 - .100 (.063 - 2.54)
.060 in. (1.50 mm)
.015 in. (0.40 mm)
VIEW A-A
CONDUCTOR CRIMP
BIRDCAGE
VIEW B-B
INSULATOR CRIMP
.100 IN. (2.54 mm) MIN.
CRIMP HEIGHT
CRIMP WIDTH
A STEP AHEAD

Common Contact System Technical Manual
Solid Contacts
Pin: Copper alloy
Socket: Copper alloy with stainless steel sleeve
Finish: Nickel plating
Optional: Gold plating is available for dry circuit applications
Stamped & Formed Contacts
Pin: Copper alloy
Socket: Copper alloy with stainless steel sleeve
Finish: Nickel plating
Optional: Gold plating is available for dry circuit applications
Dielectric Withstanding Voltage
Current leakage less than 2 milliamps at 1500 VAC.
Insulation Resistance:
1000 megohms minimum at 25 0 C.
Current Rating (Contact current rating @ 125 0 C (continuous)
Size 20: 7.5 amps
Size 16: 13 amps
Size 12: 25 amps
Size 8: 60 amps
Size 4: 100 amps
Submersion:
Properly wired and mated connection will withstand immersion under three feet of water without loss of electronic qualities or leakage.
Fluid Resistance:
Connectors show no damage when exposed to most fluids used in industrial applications.
Vibration:
No unlocking or unmating and exhibits no mechanical or physical damage after sinusoidal vibration levels of 20 G’s at 10 to 2000 Hz in each of the three mutually perpendicular planes. No electrical discontinuities longer than 1 microsecond.
Temperature:
Operative at temperatures from -55 0 C to +125 0 C. Continuous at rated current.
Contact Retention:
Contacts withstand a minimum load of:
20 lbs. (89N) for size 20
25 lbs. (111N) for size 16
30 lbs. (133N) for size 12
35 lbs. (156N) for size 8
35 lbs. (156N) for size 4
Thermal Cycle:
No cracking, chipping or leaking after 20 test cycles from -55 0 C to
+125.
Durability:
No electrical or mechanical defects after 100 cycles of engagement and disengagement.
CONTACT
SIZE
WIRE GAUGE
AWG(mm 2 )
20
16
12
8
4
22 (.35)
20 (.50)
18 (.80)
16 (1.0)
20 (.50)
18 (.80)
16 (1.0)
14 (2.0)
14 (2.0)
12 (3.0)
10 (5.0)
8 (8.60)
10 (5.60)
6 (13.0)
TEST CURRENT
(AMPS)
RESISTANCE (mV)
SOLIDS
18
25
25
60
60
100
7.5
10
13
13
5.0
7.5
7.5
7.5
60
60
N/A
60
60
60
60
60
60
60
60
60
60
60
RESISTANCE (mV)
STAMPED & FORMED
100
100
100
N/A
N/A
N/A
100
100
100
100
100
100
100
100
CONTACT SIZE
#20
#16
#12
#8
#4
RECOMMENDED WIRE INSULATION O.D.
N-SEAL E-SEAL
.053 - .120
(1.35 - 3.05)
.088 - .145
(2.24 - 3.68)
.134 - .170
(3.40 - 4.32)
.190 - .240
(4.83 - 6.10)
.280 - .292
(7.11 - 7.42)
N/A
.053 - .120
(1.35 - 3.05)
.097 - .158
(2.46 - 4.01)
N/A
N/A
A STEP AHEAD

Common Contact System Technical Manual
STAMPED AND FORMED
Deutsch Stamped and Formed contacts are designed for use where wire termination costs are of primary concern without sacrificing reliability of electrical circuits.
DESIGN AND MATERIALS SELECTION
Deutsch engineers have combined the process of superior material selection with outstanding mechanical Cad-Cam
Designs to present stamped and formed contacts that exceed the demands of today’s truck and off-highway electrical systems.
The selection of copper alloys, finished after forming with nickel plating provides superior durability, performance, corrosion and oxidation resistance.
To achieve air-tight crimps that eliminate the need to solder after wire terminations, Deutsch engineers have specified that the core-wing ends be formed in the direction of the crimp, thus assuring resistance to crimp relaxation and displacement of metal, crimp after crimp.
Deutsch socket tines are protected by a closed entry stainless steel sleeve, to ensure controlled contact pressure for maximum conductivity with minimum surface wear.
In keeping with the Deutsch commitment to total quality, all stamped and formed contacts are manufactured using SPC controls and are subjected to extensive programs of rigid testing, including field performance feedback.
FEATURES
Stainless Steel Socket Sleeve
Contact Tines are in Socket Member, Not Pin
No Lances / Tangs
Bullet (rounded) Pin Nose
Nickel Plating
Plated After Forming
Optional Gold Plating
No Individual Wire Seal Grommets
Pre-Bent or Compound Arch Core Wings
Improved Die Stop Gap
Off-Set Configuration
Copper Alloy Materials
BENEFITS
Provides closed entry design preventing probe damage.
Terminal contact points are protected from handling and assembly damage.
Contact retention is designed in the connector body, eliminating retention problems during handling and rework.
Prevents mismating and bent pins.
Reduces oxidations, thus improving conductivity performance.
No base metal is exposed to corrosion.
Available for dry circuit application.
Wire seals are designed as an integral component of the connector, thus reducing wire terminating costs.
Provides an air-tight crimp joint.
Allows application die to position wire for proper crimp length.
Provides center wire alignment between conductor and insulation.
Prevents material relaxation over time, providing reliable crimp joints and increased durability.
SIZE
20
20
20
20
16
16
16
16
16
16
16
16
12
12
STAMPED & FORMED CONTACT
PART NUMBERS
PIN
1060-20-01**
1060-20-02**
N/A
1060-20-06**
1060-14-01**
1060-14-10**
1060-16-01**
1060-16-06**
1060-16-07**
1060-16-09**
1060-16-12**
N/A
1060-12-01**
1060-12-02**
SOCKET
1062-20-01**
1062-20-02**
1062-20-03**
1062-20-06**
1062-14-01**
1062-14-10**
1062-16-01**
1062-16-06**
1062-16-07**
1062-16-09**
1062-16-12**
1062-16-14**
1062-12-01**
1062-12-02**
CARRIER
STRIP
IDENTIFICATION
20 - 01
20 - 02
20 - 03
20 - 06
14 - 16
14 - 16
16 - 18
0.5 - 1.0
0.75 - 2.0
16 - 18
1.0 - 2.5
14 - 16
12 - 14
10 - 12
WIRE SIZE
AWG (mm 2 )
(1.0 - 0.50)
14 -18
(2.0 - .75)
14 -18
(2.0 - .75)
12 -16
(2.5 - 1.0)
12 - 16
(2.5 - 1.0)
12 - 14
(4.0 - 2.0)
10 - 12
(6.0 - 4.0)
16 - 22
(1.5 - 0.35)
16 - 22
(1.5 - 0.35)
16 - 22
(1.5 - 0.35)
14 -16
(2.5 - 1.0)
14 - 18
(2.0 - .75)
14 - 16
(2.0 - .75)
14 - 18
(2.0 - .75)
16 - 20
** = Plating Codes Consult factory for custom finish needs.
For 12 Size, see 0425-041-0000 and 0425-208-0000
For 16 Size, see 0425-039-0000, 0425-059-0000, and 0425-203-0000
For 20 Size, see 0425-059-0000 and 0425-207-0000
WIRE
INSULATION
O.D. RANGE
(1.40 - 2.54)
.075 - .140
(1.91 - 3.55)
.075 - .140
(1.91 - 3.55)
.075 - .140
(1.91 - 3.55)
.075 - .140
(1.91 - 3.55)
.113 - .176
(2.87 - 4.47)
.140 - .204
(3.56 - 5.18)
.075 - .125
(1.91 - 3.15)
.051 - .085
(1.30 - 2.16)
.075 - .125
(1.91 - 3.15)
.075 - .125
(1.91 - 3.15)
.095 - .150
(2.41 - 3.81)
.095 - .150
(2.41 - 3.81)
.075 - .140
(1.91 - 3.55)
.055 - .100
RECOMMENDED
STRIP LENGTH
INCHES (mm)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.150 - .200
(3.81 - 5.08)
.175 - .225
(4.45 - 5.72)
.175 - .225
(4.45 - 5.72)
.225 - .275
(5.72 - 6.991)
.225 - .275
(5.72 - 6.99)
MIN CONT.
RETENTION
LBS (N)
(111)
25
(111)
25
(111)
25
(111)
25
(111)
30
(134)
30
(134)
(89)
25
(111)
25
(111)
25
(111)
25
20
(89)
20
(89)
20
(89)
20
MAX RATED AMPS
AT 125 0 C
CONTINUOUS
7.5
7.5
7.5
7.5
13
13
13
13
13
13
13
13
25
25
A STEP AHEAD

Common Contact System Technical Manual
SIZE PIN
SOLID CONTACT
PART NUMBERS
SOCKET
WIRE SIZE
AWG (mm 2 )
RECOMMENDED
STRIP LENGTH
INCHES (mm)
MIN CONTACT
RETENTION
LBS (N)
REF CRIMP
TENSILE
LBS (N)
MAX RATED
AMPS AT 125 0 C
CONTINUOUS
20
20
16
16
12
8
4
0460-202-20** 0462-201-20**
0460-010-20** 0462-005-20**
0460-202-16** 0462-201-16**
0460-215-16** 0462-209-16**
0460-204-12** 0462-203-12**
0460-204-08** 0462-203-08**
0460-204-04** 0462-203-04**
20
(0.50)
16-18
(1.0 - 0.75)
16-20
(1.0 - 0.50)
14
(2.0)
12-14
(3.0 - 2.0)
8-10
(8.0 - 5.0)
6
(13.0)
.156-.218
(3.96 - 5.54)
.156-.218
(3.96 - 5.54)
.250 - .312
(6.35 - 7.92)
.250 - .312
(6.35 - 7.92)
.222 - .284
(5.64 - 7.21)
.430 - .492
(10.92 - 12.50)
.430-.492
(10.92-12.50)
20
(89)
20
(89)
25
(111)
25
(111)
30
(134)
35
(156)
35
(156)
20
(89)
20
(89)
35-20
(156-89)
70
(311)
75-70
(334 - 311)
125-90
(556-400)
300
(1334)
7.5
7.5
13
13
25
60
100
* See Information Drawing 0425-205-0000. Consult factory for alternate finishes.
* Deutsch can only warrant electrical performance when proper parts, procedures and tooling from approved Crimp Termination Information Drawings are Used.
*
For size 20, 16 & 12 contacts
1) Strip specified length of insulation from wire
2) Raise selector knob and rotate until arrow is aligned with wire size to be crimped.
3) Loosen lock nut, turn adjusting screw in until it stops.
4) Insert contact, turn adjusting screw counter clockwise out until contact is flush with indenter cover. Tighten lock nut.
5) Insert wire in contact, contact must be centered between indenters, close handles until handle contacts the stop.
7) Inspect terminal to insure that all strands are in crimp barrel.
6) Release handles and remove crimped contact.
Note; tool must be readjusted for each type/size of contact or wire.
A STEP AHEAD

Common Contact System Technical Manual
For size 20, 16 & 12 solid contacts
For size 4 & 8 contacts
Field repair tool only. Not for production use.
For size 4, 8, 12, 16 & 20 solid contacts
HD16 - P/S accommodates 16 contacts
HD12 - P/S accommodates size 12 contacts
HD12-16 P/S accommodates size 16 & 12 contacts
Consult factory for availability and sources
A STEP AHEAD

Common Contact System Technical Manual
All Strands Captivated Bare Wire
Strands Extended
From Conductor Crimp
See Info.
Drawings
Recommended
Strip Length
Insulation Spaced From
Conductor Crimp Area
For crimp configuration refer to drawing 0425-2**-0000
Field Maintenance Ratched design for full cycle crimp reliability
DTT - 12 - 00
DTT - 12 - 01
DTT - 16 - 00
DTT - 16 - 01
DTT - 16 - 02
DTT - 20 - 00
DTT - 20 - 02
DTT - 20 - 03
*See information drawing for proper tool.
*Deutsch can only warrant electrical performance when proper parts, procedures and tooling from approved Crimp Termination
Information Drawings are used.
DCT12 - 02 - 00
DCT12 - 02 - 01
DCT16 - 02 - 00
DCT16 - 02 - 01
DCT1620 - 02 - 00
DCT20 - 02 - 00
Consult factory for further application information.
A STEP AHEAD

Common Contact System Technical Manual
1. Cycle the hand tool to the open position.
2. While pressing upward on the locator spring, insert the contact with the tails upward completely into the locator.
3. When correctly positioned, the contact should be located beyond flush with the edge of the hand tool and positioned on the concave polished split level crimp areas.
4. Insert the prestripped wire into the crimp area of the contact and completely cycle the tool.
5. While pressing upward on the locator spring withdraw the crimped termination.
6. The result will be a perfect termination.
7. Note that there are no unterminated wire strands, and that some strand ends can be seen at the forward edge of the crimp. Also note the insulation is gripped by the smaller secondary crimp. Distortion is at a minimum.
A STEP AHEAD

Common Contact System Technical Manual
In many electronic module designs, the use of removable contacts provides solutions of design flexibility and reduced costs. Deutsch Industrial has available a complete line of straight-reduced diameter extended pins that may be installed in any of the Deutsch family of field serviceable connectors. These solid copper alloy pins may be specified in various platings and assembled in HD30, HDP20, HD10, DRC or DT receptacles. By utilizing the tooled and readily available insert arrangements of these five connector series, the electronic designer is provided a low cost alternative to meet his application needs. Consult the Deutsch Industrial series catalogs for a complete review of connector types and insert arrangements offered.
Material
Copper alloy
Plating
90:Tin
31:Gold
P.C.B. Mounting
Consult factory for P.C.B. mounting details and pin positions.
A
END OF CONNECTOR
B
PART NUMBER A+.010 B+.010 C+.005 PRODUCT END OF CONNECTOR
0460-208-16** 1.300 .248 .025 HD30
0460-229-16** .545 .248 .025 HD10
.939
.925
0460-238-12** .714 .549 .043 DT
0460-241-16** 1.305 .160 .040 DT04-2P
.777
.677
0460-245-16** .976 .400 .041 DT04-3P .677
0460-245-12** 1.024 .500 .041 DRC 1.063
0460-257-16** .793 .248 .025
0460-208-12** 1.305 .248 .025
0460-263-16** 1.305 .248 .093
C
A STEP AHEAD

Common Contact System Technical Manual
AWG American Wire Gage - Reference National Bureau of Standards Copper Wire Table (Handbook 100) AVS.
Barrel - (1) Conductor barrel: the section of the terminal, splice or contact that accommodates the stripped conductor, or (2) Insulation barrel: The section of the terminal splice or contact that accommodates the conductor insulation.
Barrel Chamber - The bevel at the end of the conductor barrel providing for easier entry.
Belled Mouth (bellmouth) - The flared or wide entrance of a terminal, splice or contact barrel to permit easier insertion of the conductor.
Bifurcated Contact - Describes lengthwise slotting of a flat spring contact as used in a printed circuit edge connector.
Circumferential Crimp - The type of crimp where the crimping dies completely surround a barrel resulting in symmetrical indentations in the barrel.
Closed Entry - A contact or a contact cavity design in the insert or body of the termination assembly which limits the size and position of the mating contact or printed circuit board to a predetermined dimension.
Contact - The conductive element in a termination assembly which mates with a corresponding element for the purpose of transferring electrical energy.
Contact, Bellows - A contact in which a multileaf spring is folded. This provides more uniform spring rate over the full tolerance range of the mating unit.
Contact, Crimp - A contact whose conductor barrel is a hollow cylinder accepting the conductor. After a bared conductor is inserted, a crimping tool is applied to swage or form the contact metal firmly against the conductor. An excellent mechanical and electrical contact results. Often referred to as a solderless contact.
Contact, Dressed - A contact with a permanently attached contact retaining member.
Contact, Female - A contact into which the mating contact is inserted. Similar in function to a socket contact.
Contact, Fixed - A contact permanently included in the insert material. It is mechanically locked, cemented or embedded in the insert.
Contact, Insertable / Removable - A contact that can be mechanically joined to or removed from an insert. Usually special tools lock the contact in place or remove it for repair or replacement.
Contact, Male - A contact of design to make contact by insertion into a mating contact. Similar in function to a pin contact.
Contact, Nude - A contact with a contact retainer that remains in the insert at all times.
Contact, Open Entry - A socket whose engaging end is split and therefore vulnerable to distortion or damage from test probes or other wedging devices.
Contact, Pin - Male-type contact designed to fit inside the mating female contact member.
Contact, Sheet-Metal - Contacts made by stamping and bending sheet metal rather than by the machining of metal stock.
Contact, Socket - A female-type contact (usually completely surrounded by insert material).
Contact, Solde r - A contact which has a cup, hollowcylinder eyelet or hook to accept a conductor and retain the applied solder.
Contact Area - The area in contact between two conductors, two contacts or a conductor and a contact permitting the flow of electricity.
Contact Arrangement - The number, spacing and arrangement of contacts in a termination assembly.
Contact Engaging and Separating Force - Force needed to either engage or separate mating contacts.
Contact Float - The overall side play and/or angular displacement of contacts within the insert cavity.
Contact Inspection Hole - A hole in the cylindrical rear portion of contact used to check the depth to which a conductor has been inserted. Crimp-type contacts usually have inspection holes; solder-types seldom do, except larger sizes in which the hole’s function is to allow solder and air to bleed out during soldering.
Contact Resistance - Electrical resistance of a pair of engaged contacts. Resistance may be measured in ohms or millivolt drop at a specified current over the engaged contacts.
Contact Retainer - A device either on the contact or in the insert to retain the contact in an insert or body.
Contact Retention - The axial load in either direction which a contact can withstand without being dislodged from its normal position within an insert or body.
Contact Shoulder - The flanged portion of the contact which limits its travel into the insert.
Contact Size - An assigned number denoting the size of the contact.
A STEP AHEAD

Common Contact System Technical Manual
Contact Spacing - The spacing between the centers of contacts within an insert.
Contact Spring - The spring placed inside the socket-type contact to force the pin into position of positive intimate contact. Depending on the application, various types are used, including leaf, cantilever, napkin, ring, squirrel cage and “Chinese-finger” springs. All perform the function of wiping and establishing good contact. Various metal alloys are used. For example, beryllium copper is used where high conductivity and long life are required.
Stainless steel, while its conductivity is only about two percent is used in high temperature applications.
Contact Wipe - The distance of travel (electrical engagement) made by one contact with another during its engagement or separation or during mating or unmating of the connector halves.
Crimp - The physical compression (deformation) of a contact barrel around a conductor to make an electrical and mechanical connection to the conductor.
Crimping - a pressure method of mechanically securing a terminal, splice or contact to a conductor.
Crimping Die - Portion of the crimping tool that shapes the crimp.
Crimp Tool - Mechanism used for crimping.
Engaging and Separating Force - Force required to either engage or separate mating contacts or connectors.
Extraction Tool - A device used for extracting removable contacts from a termination assembly.
Flag Terminal - Terminal having a tongue protruding from the side of the barrel.
Flange Spade Terminal - A terminal whose tongue edges are turned at an angle to the plane of the tongue.
Grid Spaced - The arrangement of contacts in a multiple contact termination assembly by spacing in a geometric pattern.
Hermaphroditic Contact - A contact design which is neither pin nor socket and which mates with another contact of the same design. The contacts may be arraigned as male and female contacts as for pins and sockets. Hermaphroditic contacts may also be used in a manner such that one half of each contact mating surface protrudes beyond the connector interface and both mating connectors are identical.
Hook Terminal - Terminal with a hook-shaped tongue.
Indenter - That part of a crimping die, usually the moving part, which indents or compresses the contact barrel.
Insertion Tool - (1) A device used to insert contacts into a connector or junction. (2) A device used to insert taper pins into taper pin receptacles.
Inspection Hole - A hole placed at one end of a barrel to permit visual inspection to see that the conductor has been inserted to the proper depth in the barrel prior to crimping.
(See Contact Inspection Hole.)
Insulated Terminal - Terminal having its barrel and insulation support or grip, if used, covered with a dielectric material.
Insulation Crimp - (1) The physical deformation of an insulation sleeve covering a terminal or splice and the adjacent conductor insulation to hold the sleeve in place
(2) Shape combination of insulation sleeve to terminal or splice and conductor insulation after crimping.
Insulation Grip - The portion of the barrel which is closed or compressed around the conductor insulation.
Insulation Piercing Terminal - A terminal with a device which punctures the insulation of the conductor and makes contact with or enters into the conductor.
Insulation Support - The portion of the barrel corresponding to an insulation grip except that it is not compressed around the conductor insulation.
mm2 “millimeters squared” - European Wire Size
Standards (ref. DIN 72551-6 and ISO 6722-3).
Maximum Conductor Operating Temperature
(MCOT) - Ambient temperature plus temperature rise due to passage of electric current.
Nest - The portion of a crimping die which supports the barrel during crimping.
Offset Terminal - Terminal whose tongue is forward of, and whose stud hole is offset from, centerline of terminal barrel.
Plating - The overlaying of a thin coating of metal on components to improve conductivity, provide for easy soldering, and prevent rusting or corrosion.
Pre-Tinned - Solder applied to either or both the contact and conductor prior to soldering.
Pull-Out Force - Force necessary to separate a conductor from a contact or terminal, or a contact from a termination assembly, by exerting a pull along the axis of the conductor and the termination.
Range, Wire - The sizes of conductors accommodated by a particular barrel. Also the diameters of insulated conductors accommodated by a sealing grommet.
A STEP AHEAD

Common Contact System Technical Manual
Ratchet Control - A device to ensure the full crimping cycle of crimping tools.
Sealing Plug - A plug which is inserted to fill an unoccupied contact aperture in a termination assembly. Its function is to seal all unoccupied apertures in the assembly, especially in environmental connectors or junctions.
Seamless Terminal or Splice - Terminal or splice conductor barrel made without an open seam.
Serration - Deformation of the inside surface of a conductor barrel to provide better gripping of the conductor or on the outside of the conductor body to provide better gripping of the conductor.
Service Rating - The maximum voltage or current which a termination is designed to carry continuously.
Socket Contact Sleeve - A sleeve that holds the contact spring in the correct position within the socket contact and provides a smooth exterior surface.
Solderless Connection - The joining of two metals by pressure without the use of solder, braze or any method requiring heat.
Strand - A single uninsulated wire.
Strip - To remove insulation from a connector.
Swedging - A term for crimping.
Taper Pin - A pin-type terminal having a tapered end designed to be impacted into a tapered female terminal.
Temperature Coefficient of Resistivity - The change in resistance (electrical) per degree change in temperature.
(It is usually signified by the symbol for alpha.)
Terminal - A device designed to terminate a conductor in order to establish electrical connection.
Wiping Action - (See Contact Wipe.) Action of two electrical contacts which come in contact by sliding against each other.
A STEP AHEAD

INDUSTRIAL
3850 Industrial Avenue, Hemet, California 92545 Tel.: (951) 765-2250 - Fax: (951) 765-2255
Web: www.deutsch.net - Edition 01/2009
A STEP AHEAD

Tooling Overview
Benefi ts of Crimping
Crimp Inspection
Automated Tooling
Hand Tools
Removal Tools
Series Specifi c Tools
PG 132
PG 132
PG 132
PG 133-134
PG 135-136
PG 137-137
PG 138-139
How To Instructions PG 139-141
131

Deutsch Tooling
Deutsch Industrial manufactures two types of contacts, solid and stamped & formed. Both styles of contacts are designed for crimp style terminations, no solder is required or recommended. A crimp style termination displaces the wire strands creating a superior bond between the wire and the contact.
Deutsch offers several types of tools to assist with hand and production wire crimping, wire insertion and removal and wedgelock/ terminal position assurance removal. The tools are specifi c to the solid contacts or the stamped & formed contacts. To ensure a proper crimp and achieve the highest performance specifi cations, Deutsch contacts must be crimped with Deutsch tooling.
Deutsch can only warrant electrical performance when proper parts, procedures, and tooling are used.
 Benefi ts of Crimping
Mechanically crimping contacts is the dominant wire termination method, for some very good reasons:
1. Since no wet process is involved, corrosion is not a problem. No adhesive, fl ux, or additives are used.
2. Strength, accuracy and overall reliability of a crimped contact are controlled by the crimp tool, not the operator. The fi eld tools (except size 4 solid style) release the contact only after the full crimping cycle is completed.
3. The crimp tool is universal, accepts both pins and sockets of many sizes.
4. Crimping can be done anywhere, without special preparation. Terminations are replaced or modifi ed in the fi eld exactly the same as in the shop, using the same tools and the same techniques, and with the same ease of operation and certainty of results.
5. Total installed and maintenance costs are lower.
 Solid Contact Crimp Inspection
Crimp centered between the inspection hole and crimp barrel end
Conductor strands are visible through inspection hole
Conductor strands not visible
Correct insulation gap
(.100” max)
Acceptable Crimp
Flayed wire
Unacceptable Crimps
132
 Stamped & Formed Contact Crimp Inspection
All strands captured
Bare wire strands extended from conductor crimp
Conductor strands not visible on both sides crimp
Conductor strand not captured
Insulation spaced from conductor crimp area
Acceptable Crimp Unacceptable Crimps
A STEP AHEAD
Conductor strands bent and not completely captured

Deutsch Tooling
For higher production volumes, Deutsch offers a pneumatic power crimp tool for the solid contacts, and applicator dies for stamped & formed contacts. The HDP-400, the pneumatic solid crimp tool, is a fast, bench-top tool that crimps all of the contacts in the Deutsch Industrial Common Contact System. The HDP-400 has a foot control, and easy-to-change dies and locators for each contact size. Deutsch’s stamped & formed applicator dies are heavy duty mini-dies that work in many industry standard presses. Deutsch’s applicator dies offer simple adjustments and the fl exibility to accept different sized
Deutsch contacts and wire gauge.
 Automated Tooling for Solid Contacts
Tool P/N
HDP-400
Contact Size
4
8
12
16
20
Contact Part Number
0460-204-0490
0462-203-04141
0460-204-08141
0462-203-08141
0460-204-12**
0460-203-12**
0460-202-16**
0462-201-16**
0460-215-16**
0462-209-16**
0460-202-20**
0462-201-20**
 HDP-400 Tooling Accessories
Go-No-Go Gauges
Part Number
GA20N
450GA-16N
450GA-12N
GA8-SPEC
450GA-4-SPEC
HDP-400 Dies and Locators
Crimp Tool Part Number
HDP-400
Go-No-Go Gauges
HDP-400 Size 20
HDP-400 Size 16
HDP-400 Size 12
HDP-400 Size 8
HDP-400 Size 4
Drawing Number Reference
0425-205-0000
133
A STEP AHEAD

134
Deutsch Tooling
 Automated Tooling for S&F Contacts
Tool P/N
DCT12-02-00
DCT12-02-01
DCT16-02-00
DCT1620-02-00
DCT20-02-00
DCT1620-02-00
Contact Size Contact Part Number
12
16
1060-12-01**
1062-12-01**
1060-12-02**
1062-12-02**
1060-16-01**
1062-16-01**
1060-16-06**
1062-16-06**
20
1060-20-01**
1062-20-01**
 DCT Tooling Accessories
Bolster plate for mounting Deutsch DCT applicators to AMP K press
Part Number Bolster Plate Accessories
BOLSTER PLATE
BOLSTER PLATE BAR
BOLSTER PLT CLAMP
Bolster Plate
Bolster Plate Bar
Bolster Plate Clamp
Oiler for DCT Series applicators
Part Number
20000082
E807
Oiler Accessories
Oiler Unit
Terminal Lubricant
DCT Applicator Punches and Anvils
Applicator Part Number
DCT12-02-00
DCT12-02-01
DCT16-02-00
DCT1620-02-00
DCT20-02-00
Drawing Number Reference
0425-208-0000
0425-041-0000
0425-203-0000
0425-059-0000
0425-207-0000
A STEP AHEAD

Deutsch Tooling
For fi eld service, prototype, and low-volume production, Deutsch offers several easy-to-use hand crimp tools for both solid barrel and stamped & formed contacts. All Deutsch hand crimp tools provide a tight, complete crimp with minimal effort.
The HDT-48-00, the most commonly used tool for solid contacts, crimps a wide range of contact sizes with no need to change out dies or locators. It provides a symmetrical four indent crimp, is compact and easy-to-use for fi eld service, yet sturdy and reliable enough for low volume production. Hand crimp tools for stamped & formed contacts are wire gauge specifi c and simultaneously crimp the insulation and conductor, saving time and effort during fi eld service.
 Hand Tools for Solid Contacts
Av ail able throug h
LA
D D Industri es
HDT-04-08 HDT-48-00
Contact Size Contact Part Number Tool Part Number
4
8
0460-204-0490
0462-203-04141
0460-204-08141
0462-203-08141
HDT-04-08
HDT-04-08
12
0460-204-12**
0460-203-12**
HDT-48-00
HDT-1561
HDT-50-00
HDT-48-00
16
0460-202-16**
0462-201-16**
0460-215-16**
0462-209-16**
HDT-1561
20
0460-202-20**
0462-201-20**
HDT-50-00
HDT-48-00
HDT-1561
HDT-50-00
HDT-50-00
Crimp Type
Two Indent Crimp
Two Indent Crimp
Four Indent Crimp
Two Indent Crimp
One Indent Crimp
Four Indent Crimp
Two Indent Crimp
One Indent Crimp
Four Indent Crimp
Two Indent Crimp
One Indent Crimp
HDT-1561
 HDT-48-00 Hand Tool Accessories
HDT-48-00 Adjustment Screw and Locking Nut
Part Number Crimp Tool Replacement Part
0426-209-0000 Adjustment Screw and Locking Nut
M2700-395-10 Locking Nut helpful hint
Go no go gauges are used to inspect crimp tooling.
The G454 gauge is used with the HDT-48-00 hand tool.
Part Number Description
HDT-48-00 Go-No-Go Gauge
A STEP AHEAD
135

Deutsch Tooling
 Hand Tools for Stamped & Formed Contacts
DTT-12-00
Contact Size Contact Part Number Tool Part Number
12
1060-12-01**
1062-12-01**
1060-12-02**
1062-12-02**
DTT-12-00
DTT-12-01
16
1060-16-01**
1062-16-01**
1060-16-06**
1062-16-06**
DTT-16-00
(14-16 AWG)
DTT-16-01
(18 AWG)
20
1060-20-01**
1062-20-01**
1060-20-02**
1062-20-02**
DTT-20-00
DTT-20-02
DTT-16-00
DTT-16-01
DTT-20-00
DTT-20-02
 DT/RT1
The DT/RT1 is a multi-use tool with a small hook on one end to remove the wedgelock, and a small screwdriver on the other end to push back the locking fi ngers and release the contact. The DT/RT1 is a helpful tool for the DT, DTM, DTP, DTV, DRB, and STRIKE series of connectors.
136
A STEP AHEAD

Deutsch Tooling
 Removal Tools
Deutsch Industrial removal tools are designed to simplify contact removal and fi eld service repair in all connectors that utilize a round shoulder contact retention system. Removal tools are compact, easy-to-use, and manufactured of heavy duty plastic to remove contacts without damage to the wire, insulation, connector seals, or connector body. The removal tools are required for wire removal in the DTHD, Jiffy Splices, HD10, HDP20, HD30, DRC, AEC, and WT Series.
Removal Tool Part Number
0411-027-0405
Contact Size
Size 4
Wire Gauge Range
4 AWG
Color
Black
114009 Size 4 6 AWG White
114008
0411-353-0805
114010
0411-337-1205
0411-291-1405
0411-310-1605
0411-336-1605
0411-240-2005
Size 14
Size 16
Size 16
Size 20
Size 8
Size 8 for HD Box
Size 12
Size 12
8-10 AWG
8-10 AWG
12 AWG
12-14 AWG
Extra Thin Wall
(E-Seal)
14-16 AWG
16-18 AWG
16-18 AWG
Extra Thin Wall
(E-Seal)
20-24 AWG
Green
Light Blue
Dark Blue
Red
Green
Green
Extended
Yellow
Orange helpful hint
A contact removal tool taped or tie wrapped to the harness will make it easily available should repairs be needed.
137
A STEP AHEAD

138
Deutsch Tooling
 Crimp Tools for STRIKE Series
Contact Size
12-20
12
16
20
Contact Style
Solid
Stamped & Formed
Stamped & Formed
Stamped & Formed
Hand Crimp Tool
HDT-48-00
DTT-12-00, DTT-12-01
DTT-16-00, DTT-16-01,
DTT-16-02
DTT-20-00, DTT-20-02
Production Crimp Tool
HDP-400
DCT12-02-00, DCT12-02-01
DCT1620-02-00
DCT1620-02-00
 Assembly/Removal Tools for STRIKE Series
Tool Part Number
SRK-RT-02
SRK-RT-02-G2
SRK-RT-06
SRK-RT-06-G2
SRK-MT-02
SRK-RT-01
Connector
Receptacle
Receptacle
Plug
Plug
Description
TPA removal tool for receptacles
Not for use with 18 cavity insert
TPA removal tool for receptacles
For use with 18 cavity insert
TPA removal tool for plugs
Not for use with 18 cavity insert
TPA removal tool for plugs
For use with 18 cavity insert
TPA mounting tool for receptacles Receptacle
Plug and Receptacle
Field service removal tool (TPA or contacts) for plugs and receptacles
A STEP AHEAD

Deutsch Tooling
 Tools for IMC and Quick Connect Series
The Industrial Micro Connect and Quick Connect Series use special contacts and tools. The contacts are smaller and designed for high pin density. Removal tools along with multiple crimp tools are available and are designed to work with the smaller contacts and tighter pin arrangements. The common contact system and tools are not compatible with the IMC or QC Series.
Part Number
MH860
86-5
AF8-TH163
AMSC22/1
AMSC20/1
AMSC16/A/1
6757-201-2201
6757-201-2001
6757-201-1601
Tools for Solid Contacts
Adjustable Hand Crimp Tools
QC/IMC #22 crimp tool, adjustable AWG ranges, requires 86-5
QC/IMC crimp tool positioner for MH860
QC/IMC #20 and #16 crimp tool, adjustable AWG ranges
Single Gauge Hand Crimp Tools
QC/IMC #22 crimp tool, low cost, only crimps 22 AWG wire
QC/IMC #20 crimp tool, low cost, only crimps 20 AWG wire
QC/IMC #16 crimp tool, low cost, only crimps 16 AWG wire
Insert/Removal Tools
Insert/Removal Tool #22
Insert/Removal Tool #20
Insert/Removal Tool #16
 Wire Stripping
Step 1:
1. Choose the correct
AWG for the contact being used.
2. Measure from the end of the wire the recommended strip length according to the contact size.
3. Place the wire into a stripping tool at the recommended strip length.
Strip the wire according to stripping tool instructions.
Step 2:
1. After stripping, a small piece of the insulation should come off.
2. Check for any broken strands or for a dent in the wire. If either exist, the wire is damaged and should be cut and stripped again.
Step 3:
Measure the exposed strands to be sure the crimp length is correct. helpful hint
Leaving the stripped portion of the insulation on the wire until prior to crimping will avoid fl ayed wire strands.
Incorrect
Correct
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A STEP AHEAD

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Deutsch Tooling
 Crimping with the HDT-48-00 Hand Tool
Tool must be adjusted for each type/size of contact.
Step 1:
1. Strip insulation from wire.
2. Raise selector knob and rotate until arrow is aligned with wire size to be crimped.
3. Loosen locknut, turn adjusting screw in until it stops.
Step 2:
Insert contact with barrel up. Turn adjusting screw counter clockwise until contact is fl ush with indentor cover. Tighten locknut.
Step 3:
1. Insert wire into contact.
Contact must be centered between indentors. Close handles until crimp cycle is completed.
2. Release handles and remove crimped contact.
 Crimping with DTT Style Hand Tools (size 16 & 20)
Step 1:
Cycle the hand tool to the open position. Place the contact into the correct die nest.
Step 2:
Partially close the tool until the contact is held in place.
Step 3:
Insert the prestripped wire into the crimp area of the contact.
Step 4:
Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete.
A STEP AHEAD

Deutsch Tooling
 Crimping with DTT-12-01 Hand Tool
Insulation diameters Proper contact position, front view
Proper contact position, side view
Insulation selector
Step 1:
Cycle handles to release ratchet and fully open crimp jaws. Pull out insulation selector and push into proper diameter using the chart below.
Wire Type Insulation Selector
10 TXL
10 GXL
10 SXL
5.0 mm 2
6.0 mm 2
.150-.170
.160-.180
.170-.205
.160-.180
.170-.205
Step 2:
1. Insert contact into locator. Adjust alignment and width of crimp wings if necessary to ensure capture by crimp jaws.
2. Insert stripped wire into the contact. Close crimp tool until full-cycle ratchet control releases.
 Crimping with DTT-12-00 Hand Tool
Step 1:
Cycle the tool to release ratchet and open tool. Lift the locator gate, and place the contact into the correct die nest.
Adjust alignment of crimp wings to ensure capture by crimp jaws.
Step 2:
Partially close the tool until the contact is held in place.
Step 3:
Insert the prestripped wire into the crimp area of the contact.
Step 4:
Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete.
A STEP AHEAD
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